What a lot of people don't understand is that when something is rated 90degree celsius, it means it'll get 90 degree celsius when running at the full load specified. The load limitations are because the heat generated by said load and not because of some magic number the manufacturers and engineers come up with. Therefore they build the switch to be able to heat up to 60 degree celsius (or whatever the rating is) and by doing that it can run a 500W load. Have you noticed that the 1000W dimmers are same as the 500W, but they have a heat sink that cools off the switch even when running a higher load? Therefore keeping the temperature at what the dimmer can take and still operate.
A transformer at 90 degree rise will be much bigger than same KVA transformer at 140 degree rise because the 90 degree has to be build to not heat more than that when at full load. So basically the manufacturer takes a 150KVA at 140 degree and make it 112.5KVA at 90 degree. Which basically is what a 150KVA will heat if the load doesn't exceed 112.5.
And last, remind your customer 90 degree (and even 75 or 60) is pretty darn hot.
Have a call to go to tomorrow where the customer says the Leviton single pole slide dimmer in her kitchen is getting hot after the lights haev been on all day. We just installed this a couple of months ago. It is in a 2 gang box with another dimmer. The one getting hot is rated for 600W (500W when installed in a box with 2 dimmers). It has 6 five inch recessed cans with 50W R20 flood lamps in each can for a total of 300W total load.
I don't really want to have to go to a 1000W dimmer if I can avoid it.
Any suggestions as far as things to suspect for the cause?
No the connections aren't loose.